Flaps and ailerons at last 19th May 2007.

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All the bits to make the Ailerons and Flaps. First job was the aileron counter weights. It came as one chunk of soft lead , I cut it in half with a hacksaw and then filed it to size. Then I had to drill 6 3/16" holes in each one. Quite easy to do as long you clean the drill about 6 times for each hole. HSS drills are not really suited to drilling through 25mm of lead, but I took my time and finished up with 12 nice clean holes. Last shot a completed assembly , it all went together perfectly no gotchers here.

May the 28th 2007 finishing off the right aileron , there is a lot of work in these things.

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The drive rib and counter balance. The drive end ready for the rib.

Here is a shot of my experiment with the tip trimming, I cut the skin a couple of inches long to see how the tip rib would fit in before I cut to final size , as I had heard it was a pain to fit. Every thing seemed good so I went ahead and made the final cut and as you can see in the last photo in the bottom row the tip rib fitted in perfectly.

Last shot top row the skin trimmed ready for filing. Like the elevators I made several small cuts right around until there was only about 2mm left then I made the final cut.

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Counter balance in minus the lead weight. Drive rib in and finally the tip rib in.

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The Right Aileron mounted on the wing with mechanism connected , the action is as smooth as silk with "ZERO" play , "This is one happy builder". The Left Aileron under construction. I was not planning to photograph the Left Aileron but I thought I would try a different camera to see how it went. I normally use my Panasonic FZ30 , These were taken with a Casio EX-Z75. Same resolution, which proves that Mega Pixels are not always the same. Although to be fair I should have used the FZ-30 under the same lighting conditions.

20th June 2007 Flaps almost finished.

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This is the RH flap ready for riveting I have finished the LH one but have not mounted it on the wing yet, that should all happen this weekend and I will start on the fuselage next week.

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Two monster flaps I guess this is the reason the Sonex can fly so slowly.

This all went together beautifully , it might seem like a lot of work but it's very enjoyable work.

Now on to the Fuselage

Flap drive system 20 April 2008 .

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Bending the flap handle. The handle installed on the drive shaft. The plans call for a piece of 3/16" x 1" aluminium, I did not have anything like that so I used 2 pieces of scrap 1/8" glued together, they were part of some angle I had cut up earlier so they went together to form a nice round edge.

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The bearing blocks on the port side had to fit in a narrow section of the shaft so I had to saw about 3mm off each side. I bolted it to a piece of scrap wood and cut it in my compound saw. The blocks in position you can just see the bottom of the flap handle.

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All finished shown in the neutral position , first notch is 15 degrees and last notch is 30 degrees , a lot of people have modified this to have 10 20 and 30 degrees and I was going to do this but in the end I kept it standard and if I feel later on I want the 3 stages I can easily change it. Completed flap handle.